Use of silicones to improve fiberglass insulation products

Abstract

Dispersions of reactive polysiloxanes are applied to fibrous products, such as construction panels to provide improved properties, like better resistance to staining and discoloration and better adhesion of facer layers The reactive polysiloxane may be applied directly to the fibrous product or mixed into binder compositions prior to application; and may be applied substantially uniformly or non-uniformly. The construction panels may form wall and / or ceiling panels. The reactive polysiloxane may include polysiloxanes functionalized with any of hydrogen, amino, hydroxyl or carboxyl reactive functionalities.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of provisional patent application Ser. No. 61 / 429,677, filed Jan. 4, 2011 and titled: Water Resistant Insulation and Method, which is incorporated herein in its entirety.BACKGROUND OF THE INVENTION[0002]The present invention relates generally to the field of fiberglass insulation, including panels such as ceiling boards and tiles, wall panels, duct boards, pipe and molded or formed insulation products, and methods to improve the properties thereof, more specifically, water resistance, stain resistance and adhesion of facer layers.[0003]Fibrous insulation and construction panels are typically manufactured by fiberizing a molten composition of polymer, glass or other mineral material to form fine fibers and depositing the fibers on a collecting conveyor to form a batt or a blanket. Mineral fibers, such as glass fibers, are typically used in insulation products. A binder composition may optionally be used ...

AI Technical Summary

Benefits of technology

[0008]In general, the invention relates to the addition of silicone additives to fibrous insulation products. The addition results in certain improved properties that are unexpected; for example, improved water resistance, improved stain resistance and improved adhesion with facer layers.

[0024]In one embodiment, an insulation product having fibers bound by a binder is provided. The binder can include silicone emulsion or polyglycerine as an additive to the binder chemistry to improve water resistance of the final insulation products. The weight percentage of the binder additives is in the range of up to 2.5% by weight of fiber material (e.g., glass). In one preferred embodiment, the weight percentage of the binder additives is approximately 0.01% to approximately 1% weight of fiber material (e.g., glass).

[0025]A feature of the present invention is ceiling tiles and wall panels with improved resistance to water staining, such as may be caused by leakage or high moisture environments. Another feature is improved adhesion of the facer layer to the fibrous substrate, possibly resulting in savings of adhesive costs.

[0026]Another feature is the use of additives like silicones or polyglycerine to improve water resistance properties like absorption and wicking tension.

Problems solved by technology

However, in some environments, moisture may be present and may infiltrate the insulation.

This can cause the insulation to be less effective than intended and cause other issues.

A problem with some construction panels is the tendency for water or moisture to seep or bleed through the fiberglass panel and cause staining and / or discoloration of the finished surface.

This problem may occur as a result of a leak in a plumbing system or in high humidity areas in the absence of any leaks.

This is particularly troublesome when the water or moisture dissolves and washes brown or otherwise colored binder products from the fiber matrix and into the finish layer.

Another problem arises when adhesives are used to apply finish layer or facer to the underlying fiberglass panel.

Most typically with hydrophilic surfaces, the adhesives are absorbed quickly into the fiberglass, requiring excessive amounts of adhesive or causing poor adhesion of the finish or facer layer.

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